Development of continuous multiphase microreactors for the production of fine chemicals

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Many fine chemicals and pharmaceuticals are produced by solvent-intensive batch or semi-batch processes increasing costs and environmental impact. In comparison, continuous-flow microreactors offer a large surface-to-volume ratio and intimate contact between reactants, which leads to very high heat and mass transfer rates, permitting improved reaction control and selectivity at more severe operating conditions. This and their small volume enable safer handling of hazardous reactions and unstable intermediates. The overall goal of this research program is thus to develop continuous-flow microreactor technology sufficiently flexible that it can outperform batch/semi-batch reactors for a variety of single and multiphase reactions over production scales ranging from pharmaceutical clinical trial phases I (10-50 ml/min) to III (400-600 ml/min). Focus is primarily on molecules where synthesis is highly exothermic and/or limited by interphase mass transfer since these operating conditions are more difficult to optimize. A systematic and thorough experimental program will investigate: 1) Hydrodynamics and transport phenomena of gas-liquid flow without and with solid-supported catalyst in select and distinct reactor geometries. This will lead to criteria for choosing mixing structures based on desired contacting pattern and efficiency in dissipating energy, and to robust scaling rules. 2) Ring-closing metathesis of olefins and hydrogenation of nitriles, which are catalytic reactions of central importance in organic synthesis and take advantage of leading chemical expertise at the University of Ottawa. This will synergistically use and provide information towards part 1); forming stronger ties between chemists and engineers such that catalyst/reaction and reactor design are optimized concurrently. Deploying graduate students trained within a multidisciplinary science/engineering environment will help accelerate changes to manufacturing in the pharmaceutical industry, an important contributor to Canada's economy and well-being.